THERMOSTAT INSTALLATION


  1. INSTALL THERMOSTAT


    1. A01CFVGE01

      Install a new gasket to the thermostat.

    2. Install the thermostat with the jiggle valve facing up.

      Tech Tips

      The jiggle valve may be set within 10° on either side of the prescribed position.

  2. INSTALL WATER INLET


    1. A01CCN0

      Install the water inlet with the 2 nuts .

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  3. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01CBCC

      Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.

      Torque:
      54 N*m  { 550 kgf*cm, 40 ft.*lbf }

  4. CONNECT NO. 2 RADIATOR HOSE


    1. A01CGHE

      Connect the No. 2 radiator hose to the engine.

  5. INSTALL V-RIBBED BELT


    1. A01CD3WE01

      Install the V-ribbed belt.

    2. If it is difficult to install the V-ribbed belt, perform the following procedure:


      1. Put the V-ribbed belt on every pulley except the tensioner pulley as shown in the illustration.

      2. Release the V-ribbed belt tension by turning the V-ribbed belt tensioner counterclockwise, and put the V-ribbed belt on the tensioner pulley.

        Note


        • Put the backside of the V-ribbed belt on the V-ribbed belt tensioner pulley and idler pulley.

        • Check that the V-ribbed belt is properly set to each pulley.

    3. A01CEBW

      Turn the V-ribbed belt tensioner counterclockwise and remove a 5 mm bi-hexagon wrench.

    4. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand.

  6. INSTALL FRONT BUMPER ASSEMBLY (for ALPHARD)

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  7. INSTALL FRONT BUMPER ASSEMBLY (for VELLFIRE)

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  8. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the 2 cylinder block drain cock plugs.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    3. Remove the reserve tank cap. (*1)

    4. Loosen the air drain cock plug on the water inlet housing.

    5. Add TOYOTA Super Long Life Coolant (SLLC).

      Standard capacity
      10.6 liters (11.2 US qts, 9.3 Imp. qts)

      Note

      Never use water as a substitute for engine coolant.

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

      • Squeeze the No. 1 and No. 2 radiator hoses several times. If the coolant level at the water inlet opening drops, add TOYOTA SLLC.

    6. Add TOYOTA SLLC to the reserve tank until coolant overflows from the air drain cock plug hole. Then tighten the air drain cock plug on the water inlet housing.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    7. A01CEZCE01

      Continue adding TOYOTA SLLC until it reaches the B line. (*2)

    8. Install the reserve tank cap. (*3)

    9. Run the engine at about 2000 rpm to warm it up until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. (*4)

      CAUTION:


      • When push the radiator hoses, wear protective gloves.

      • Be careful as the radiator hoses, engine and radiator are hot.

      • Keep your hands away from the radiator fans.

      Note


      • If the radiator reserve tank runs out of coolant just after the engine is started, stop the engine immediately, wait until the coolant has cooled down, and then add coolant.

      • Make sure that the reserve tank still has some coolant in it.

      • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

      • If there is not enough coolant, the engine may overheat or be seriously damaged.

      Tech Tips


      • A01CE5GE01

        If coolant comes out from the bypass hose port connected to the reserve tank, the thermostat has been opened.

      • After the thermostat has opened, idle the engine until the coolant in the reserve tank goes from being cloudy to a clear red.

    10. Stop the engine and wait until the coolant cools down. (*5)

    11. A01CFOIE01

      Check that the coolant level is between the FULL and LOW lines. (*6)

      Tech Tips


      • If the coolant level is below the LOW line, repeat steps from (*1) to (*6).

      • If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW lines.

  9. INSPECT FOR COOLANT LEAK


    1. Remove the radiator reservoir cap.

      CAUTION:

      Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    2. A01CB9EE01

      Fill the radiator and reservoir with coolant, and then attach a radiator cap tester.

    3. Warm up the engine.

    4. Pump the radiator cap tester to 118 kPa (1.2 kgf/cm2, 17 psi), and then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks.

      If there are no signs of external coolant leaks, check the heater core, cylinder block and head.

    5. Reinstall the radiator reservoir cap.

  10. INSTALL REAR ENGINE UNDER COVER RH

  11. INSTALL NO. 1 ENGINE UNDER COVER

  12. INSTALL FRONT WHEEL RH

  13. ADJUST FOG LIGHT AIMING (for ALPHARD)

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  14. ADJUST FOG LIGHT AIMING (for VELLFIRE)

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